Formation of alpha particle shields in chip packaging

ABSTRACT

A structure fabrication method. First, an integrated circuit including N chip electric pads is provided electrically connected to a plurality of devices on the integrated circuit. Then, an interposing shield having a top side and a bottom side and having N electric conductors in the interposing shield is provided being exposed to a surrounding ambient at the top side but not at the bottom side. Next, the integrated circuit is bonded to the top side of the interposing shield such that the N chip electric pads are in electrical contact with the N electric conductors. Next, the bottom side of the interposing shield is polished so as to expose the N electric conductors to the surrounding ambient at the bottom side of the interposing shield. Then, N solder bumps are formed on the polished bottom side of the interposing shield and in electrical contact with the N electric conductors.

This application is a divisional application claiming priority to Ser.No. 11/211,116, filed Aug. 24, 2005, now abandoned.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to integrated circuit packaging, and morespecifically, to using alpha particle shields in integrated circuitpackaging.

2. Related Art

In flip-chip technologies, solder bumps are typically formed on top of asemiconductor chip (i.e., integrated circuit IC). Each solder bump isformed directly on a bond pad of the chip. Then the chip is flipped facedown and then aligned to a package/substrate so that the solder bumpsare bonded directly, simultaneously, and one-to-one to the pads of thepackage/substrate (called package/substrate pads). However, for ceramicsubstrates, alpha particles (large subatomic fragments consisting of 2protons and 2 neutrons) continuously emit from the substrate and enterthe chip resulting in a large number of soft errors in the chip duringthe normal operation of the chip. Alpha particles are also generatedfrom ²¹⁰Pb contained in the solder bumps.

Therefore, there is a need for a structure (and a method for forming thesame) that reduces the number of alpha particles that enter the chip.

SUMMARY OF THE INVENTION

The present invention provides a structure fabrication method,comprising providing an integrated circuit including N chip electricpads, wherein N is a positive integer, and wherein the N chip electricpads are electrically connected to a plurality of devices on theintegrated circuit; providing an interposing shield having a top sideand a bottom side and having N electric conductors in the interposingshield, wherein the N electric conductors are exposed to a surroundingambient at the top side but not being exposed to the surrounding ambientat the bottom side; bonding the integrated circuit to the top side ofthe interposing shield such that the N chip electric pads are inelectrical contact with the N electric conductors; polishing the bottomside of the interposing shield so as to expose the N electric conductorsto the surrounding ambient at the bottom side of the interposing shieldafter said bonding the integrated circuit to the top side is performed;and forming N solder bumps on the polished bottom side of theinterposing shield and in electrical contact with the N electricconductors.

The present invention also provides a structure fabrication method,comprising providing an integrated circuit including N chip electricpads, wherein N is a positive integer, and wherein the N chip electricpads are electrically connected to a plurality of devices on theintegrated circuit; providing a semiconductor interposing shield havinga top side and a bottom side and having N electric conductors in thesemiconductor shield, wherein the N electric conductors are exposed to asurrounding ambient at the top side but not being exposed to thesurrounding ambient at the bottom side; bonding the integrated circuitto the top side of the semiconductor interposing shield such that the Nchip electric pads are in electrical contact with the N electricconductors; polishing the bottom side of the semiconductor interposingshield so as to expose the N electric conductors to the surroundingambient at the bottom side of the semiconductor interposing shield aftersaid bonding the integrated circuit to the top side is performed;forming N solder bumps on the polished bottom side of the semiconductorinterposing shield and in electrical contact with the N electricconductors; after said forming the N solder bumps is performed, bondinga ceramic substrate that includes N substrate pads such that the Nsubstrate pads are bonded to the N solder bumps, wherein thesemiconductor interposing shield comprises essentially only silicon, andwherein the semiconductor interposing shield has a thickness of at least50 μm after said polishing the bottom side is performed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-12 show the fabrication process for forming a structure, inaccordance with embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-10 show the fabrication process for forming a structure 700(FIG. 10), in accordance with embodiments of the present invention. Morespecifically, with reference to FIG. 1A, in one embodiment, thefabrication process starts out with an interposing shield 100 thatcomprises a semiconductor (e.g., silicon, germanium) layer 110. Next, inone embodiment, annular trenches 112 a and 112 b are formed in thesemiconductor layer 110. Illustratively, the annular trenches 112 a and112 b are formed using a photolithographic process. In one embodiment,the annular trenches 112 a and 112 b have a depth 113 of around 50-70μm. FIG. 1B shows a perspective view of the interposing shield 100 ofFIG. 1A.

Next, with reference to FIG. 2, in one embodiment, a dielectric film 210is formed on exposed-to-ambient silicon surfaces of the interposingshield 100 of FIG. 1A. As a result, the dielectric film 210 forms on,among other places, bottom walls and side walls of the annular trenches112 a and 112 b. Illustratively, exposed-to-ambient silicon surfaces ofthe interposing shield 100 of FIG. 1 can be thermally oxidized so as toform silicon dioxide resulting in the dielectric film 210.

Next, with reference to FIG. 3, in one embodiment, an electricallyconducting layer 310 is formed on top of the interposing shield 100 ofFIG. 2 so as to completely fill the annular trenches 112 a and 112 b.Illustratively, the electrically conducting layer 310 comprises a metal(such as copper Cu) and is formed by CVD (chemical vapor deposition),ALD (atomic layer deposition), or electrochemical plating of the metal(i.e., Cu). It should be noted that if the metal used for theelectrically conducting layer 310 is tungsten (W), a seed layer (notshown) of Ti or TiN needs to be formed first on top of the interposingshield 100 of FIG. 2 by PVD, CVD or ALD to serve as nuclei for theensuing growth of tungsten to form the W electrically conducting layer310. Likewise, it should be noted that if the metal used for theelectrically conducting layer 310 is copper (Cu), a seed layer (notshown) of TaN, Ta and Cu needs to be formed first on top of theinterposing shield 100 of FIG. 2 by PVD, CVD or ALD to serve as nucleifor the ensuing growth of copper to form the Cu electrically conductinglayer 310.

Next, in one embodiment, a chemical mechanical polishing (CMP) step isperformed on top surfaces 320 of the interposing shield 100 of FIG. 3until the dielectric film 210 is exposed to the surrounding ambient. Theresulting interposing shield 100 is shown in FIG. 4 (without the toplayer 420). What remains of the electrically conducting layer 310 afterthe CMP step resides in the annular trenches 112 a and 112 b and can bereferred to as the annular electric conductors 410 a and 410 b (FIG. 4).

Next, with reference to FIG. 4, in one embodiment, a dielectric layer420 is formed on top of the dielectric film 210 and in contact with theannular electric conductors 410 a and 410 b. Illustratively, thedielectric layer 420 comprises silicon dioxide and is formed by CVD ofsilicon dioxide.

Next, with reference to FIG. 5, in one embodiment, electric pads 510 aand 510 b are formed in the oxide layer 420 and in direct physicalcontact with the annular electric conductors 410 a and 410 b,respectively. Illustratively, the electric pads 510 a and 510 b comprisecopper and can be formed using a conventional damascene process. Morespecifically, the damascene process starts with etching trenches (whichthe electric pads 510 a and 510 b later occupy) in the oxide layer 420using a conventional lithographic process. Next, copper is deposited(e.g., by electroplating) to fill the trenches. Finally, excess copperoutside the trenches is removed by a CMP step resulting in the electricpads 510 a and 510 b as shown in FIG. 5.

Next, in one embodiment, the oxide layer 420 is recessed so that its topsurface 422 is lower than the top surfaces 512 of the electric pads 510a and 510 b as shown in FIG. 6. In one embodiment, the oxide layer 420is recessed by several thousand Å to 0.5 μm. Illustratively, the oxidelayer 420 is recessed by a wet etch using a dilute hydrofloric acidsolution (HF).

Next, with reference to FIG. 6, in one embodiment, the interposingshield 100 is aligned with a semiconductor chip (integrated circuit IC)600 such that the electric pads 622 a and 622 b of the semiconductorchip 600 are aligned with the electric pads 510 a and 510 b of theinterposing shield 100, respectively. In one embodiment, thesemiconductor chip 600 is fabricated separately from the fabrication ofthe interposing shield 100. Illustratively, the semiconductor chip 600comprises a device region 610 and a back-end-of-line (BEOL) region 620.The device region 610 can comprise devices such as transistors,resistors, and capacitors (not shown). The (BEOL) region 620 cancomprise electrically conducting lines (not shown) running in adielectric material so as to (i) electrically connect the devices of thedevice region 610 together and (ii) electrically connect the devices ofthe device region 610 to the electric pads 622 a and 622 b.

Next, with reference to FIG. 7, in one embodiment, the interposingshield 100 and the chip 600 are bonded together to form a structure 700such that the electric pads 510 a and 622 a (FIG. 6) merge together toform an electric pad 510 a,622 a and such that the electric pads 510 band 622 b (FIG. 6) merge together to form an electric pad 510 b,622 b.In one embodiment, the bonding process is performed at 350-400° C.

Next, with reference to FIG. 8, in one embodiment, the bottom side ofthe structure 700 is polished until the annular electric conductors 410a and 410 b are exposed to the surrounding ambient. Illustratively, thebottom side of the structure 700 is mechanically ground by a mechanicalgrinding process only. Alternatively, the bottom side of the structure700 is ground down by a mechanical grinding process until the annularelectric conductors 410 a and 410 b are about to be exposed to thesurrounding ambient. Then, a wet etch is performed on the bottom side ofthe structure 700 so as to expose the annular electric conductors 410 aand 410 b to the surrounding ambient.

Next, with reference to FIG. 9, in one embodiment, solder bumps 910 aand 910 b are formed on bottom side of the structure 700 and inelectrical contact with the annular electric conductors 410 a and 410 b,respectively, using a conventional solder bump formation process (alsoknown as the flip chip technologies). The resulting structure 700 isshown in FIG. 9. The solder bumps 910 a and 910 b are electricallyconnected to the annular electric conductors 410 a and 410 b viaelectric chip pads 920 a and 920 b, respectively. Illustratively, theelectric chip pads 920 a and 920 b comprises aluminum. Although notshown, between the solder bumps 910 a and 910 b and the aluminum chippads 920 a and 920 b is a ball limiting metallurgy (BLM) (illustrativelycomprising TiW/CuCr/Cu). The rest of the bottom side of the structure700 is covered by a polyimide layer 930 which is a dielectric material.

Next, with reference to FIG. 10, in one embodiment, a ceramic substrate1010 is bonded with the structure 700 such that substrate pads 1010 aand 1010 b of the ceramic substrate 1010 are bonded with the solderbumps 910 a and 910 b, respectively. Illustratively, the substrate pads1010 a and 1010 b comprises aluminum.

Next, in one embodiment, the structure 700 is placed in a package (notshown) having package pins (not shown) that are electrically connectedto the substrate pads 1010 a and 1010 b via metal lines (not shown).

In summary, with reference to FIG. 10, the interposing shield 100 issandwiched between the ceramic substrate 1010 and the semiconductor chip600. As a result, the interposing shield 100 helps reduce the alphaparticles that are generated by the ceramic substrate 1010 and enter thesemiconductor chip 600. The interposing shield 100 also helps reduce thealpha particles that are generated by the solder bumps 910 a and 910 b(i.e. Pb).

In one embodiment, the thickness 114 of the interposing shield 100 issufficiently large such that at least a pre-specified percentage ofalpha particles entering the interposing shield 100 from the ceramicsubstrate 1010 do not pass through the interposing shield 100 so as toreach the semiconductor chip 600.

It should be noted that the thickness 114 of the interposing shield 100is essentially the depth 113 (FIG. 1A) of the annular trenches 112 a and112 b of FIG. 1A. As a result, with the depth 113 (FIG. 1A) of around50-70 μm, the thickness 114 of the silicon interposing shield 100 isalso around 50-70 μm and therefore is sufficiently thick to prevent mostof the alpha particles generated by the ceramic substrate 1010 fromentering the semiconductor chip 600.

It should also be noted that the annular electric conductors 410 a and410 b provide electric paths from the solder bumps 910 a and 910 b tothe devices (not shown) of the semiconductor chip 600 (via the electricpads 510 a,622 a and electric pad 510 b,622 b, respectively). Theannular shape is chosen for the electric conductors 410 a and 410 b soas to save metal material during the step of filling the trenches 112 aand 112 b (FIG. 3) to form the electric conductors 410 a and 410 b.Moreover, because the trenches 112 a and 112 b (FIG. 3) are filled fast,the excess metal outside the trenches 112 a and 112 b (FIG. 3) are less,and therefore, the ensuing removal of the excess metal becomes easier.In general, the trenches 112 a and 112 b (FIG. 3) can have any shape andsize.

It should be noted that the solder bumps 910 a and 910 b may comprise atin-lead alloy which itself generates alpha particles. Because theinterposing shield 100 is sandwiched between the solder bumps 910 a and910 b and the semiconductor chip 600, the interposing shield 100 alsohelps reduce the alpha particles that enter the semiconductor chip 600from the solder bumps 910 a and 910 b.

In one embodiment, the structure 700 comprises a dielectric layer (notshown) that electrically insulates the electric chip pads 920 a and 920b from the silicon region of the silicon layer 110 such that there is noelectrically conducting path between the electric chip pads 920 a and920 b through the silicon region of the silicon layer 110.

In the embodiments above, there are two trenches 112 a and 112 b (FIG.1A) formed. In general, there can be N trenches formed, wherein N is apositive integer. As a result, there are N solder bumps (like the solderbumps 910 a and 910 b) electrically connected one-to-one to N electricpads (like the electric pad 510 a,622 a and 510 b,622 b) through Nelectric conductors (like the electric conductors 410 a and 410 b).

In one embodiment, with reference to FIG. 11, metal (e.g., copper)regions 1110 a, 1110 b, and 1110 c are formed in the semiconductorregions of the interposing shield 100 such that the metal regions areelectrically insulated from the electric conductors 410 a and 410 b.Because copper is better than silicon in absorbing alpha particles, theinterposing shield 100 with such embedded copper regions performs betterin preventing alpha particles from reaching the semiconductor chip 600.Illustratively, the copper regions can be formed by creating trenches(not shown) similar to the trenches 112 a and 112 b (FIG. 1A) andfilling these trenches with copper.

In one embodiment, a metal (e.g., copper) layer 1210 (FIG. 12) may beformed on the bottom side of the structure 700 of FIG. 8. Then, thesolder bumps 910 a and 910 b are formed as described above. Additionalconventional fabrication steps are needed after the copper layer isformed and before the solder bumps 910 a and 910 b are formed so thatthe copper layer is sandwiched between, and electrically insulated from,the electric conductors 410 a and 410 b and the solder bumps 910 a and910 b. The resulting structure 700 is shown in FIG. 12. Because copperis better than silicon in absorbing alpha particles, the interposingshield 100 with the copper layer performs better in preventing alphaparticles from reaching the semiconductor chip 600. It should be notedthat a dielectric layer (not shown) electrically insulates the copperlayer 1210 from the silicon regions of the silicon interposing shield100. In one embodiment, the thickness of the copper layer 1210 is aboutone third of the thickness of the silicon interposing shield 100. In oneembodiment, the thickness of the copper layer 1210 is less than 15 μmand the silicon interposing shield 100 has a thickness in a range of 30μm-70 μm. If the thickness of the copper layer 1210 is increased, thethickness of the silicon interposing shield 100 can be reduced. Thismeans that the depth 113 (FIG. 1A) of the trenches 112 a and 112 b (FIG.1A) can be reduced. In one embodiment, the copper layer has a thicknessin a range of 10 μm-15 μm, which is sufficient by itself in blockingalpha particles, and therefore, the thickness of the silicon interposingshield 100 can be less than 1 μm or even zero (i.e., silicon interposingshield 100 can be omitted).

In one embodiment, the silicon regions of the semiconductor interposingshield 100 are doped with boron atoms (using, illustratively, ionimplantation). This enhances the capability of the semiconductorinterposing shield 100 in preventing cosmic thermal neutrons frompassing through the semiconductor interposing shield 100 and reach thesemiconductor chip 600. The cosmic thermal neutrons undergo reactionswith the B that emit <2 MeV alpha particles. Therefore it isadvantageous to have this B doped region on the top of the Si interposerlayer (on the opposite side from the semiconductor device).

While particular embodiments of the present invention have beendescribed herein for purposes of illustration, many modifications andchanges will become apparent to those skilled in the art. Accordingly,the appended claims are intended to encompass all such modifications andchanges as fall within the true spirit and scope of this invention.

1. A structure fabrication method, comprising: providing an integratedcircuit including N chip electric pads, wherein N is a positive integer,and wherein the N chip electric pads are electrically connected to aplurality of devices on the integrated circuit; providing an interposingshield having a top side and a bottom side and having N electricconductors in the interposing shield, wherein the N electric conductorsare exposed to a surrounding ambient at the top side but not beingexposed to the surrounding ambient at the bottom side, wherein N is atleast 2; bonding the integrated circuit to the top side of theinterposing shield such that the N chip electric pads are in electricalcontact with the N electric conductors; polishing the bottom side of theinterposing shield so as to expose the N electric conductors to thesurrounding ambient at the bottom side of the interposing shield aftersaid bonding the integrated circuit to the top side is performed; andforming N solder bumps on the polished bottom side of the interposingshield and in electrical contact with the N electric conductors, whereinthe interposing shield comprises a shield material, wherein the shieldmaterial comprises a first semiconductor material, wherein each electricconductor of the N electric conductors comprises an electrical pad,wherein said bonding comprises bonding the integrated circuit to the topside of the interposing shield such that the N chip electric pads are inelectrical contact and direct physical contact with correspondingelectrical pads of the N electric conductors, wherein after said bondingand before said polishing, the shield material covers the N electricconductors in a manner that the N electric conductors are not exposed tothe surrounding ambient, and wherein said polishing removes a sufficientamount of the shield material to expose the N electric conductors to thesurrounding ambient.
 2. The method of claim 1, further comprising, aftersaid forming the N solder bumps is performed, bonding a ceramicsubstrate that includes N substrate pads such that the N substrate padsare bonded to the N solder bumps.
 3. The method of claim 1, wherein thefirst semiconductor material is the only semiconductor material in theinterposing shield.
 4. The method of claim 1, wherein said providing theinterposing shield comprises: providing a semiconductor layer; creatingN trenches in the semiconductor layer; filling the N trenches with anelectrically conducting material so as to form the N electricconductors, wherein the semiconductor layer, after said filling the Ntrenches is performed, comprises the interposing shield.
 5. The methodof claim 1, wherein the N solder bumps are electrically connected tocorresponding electric conductors of the N electric conductors viacorresponding electrical chip pads, and wherein each electrical chip padis disposed between and in direct physical contact with thecorresponding solder bump and the corresponding electric conductor. 6.The method of claim 3, wherein the interposing shield has a thickness ofat least 50 μm after said polishing the bottom side is performed.
 7. Themethod of claim 4, wherein said providing the interposing shield furthercomprises forming a dielectric layer on side walls of the N trenchesbefore said filling the N trenches is performed.
 8. The method of claim4, wherein each trench of the N trenches has an annular shape.
 9. Themethod of claim 3, wherein the semiconductor material consists ofsilicon.
 10. A structure fabrication method, comprising: providing anintegrated circuit including N chip electric pads, wherein N is apositive integer, and wherein the N chip electric pads are electricallyconnected to a plurality of devices on the integrated circuit; providingan interposing shield having a top side and a bottom side and having Nelectric conductors in the interposing shield, wherein the N electricconductors are exposed to a surrounding ambient at the top side but notbeing exposed to the surrounding ambient at the bottom side, wherein Nis at least 2, wherein the interposing shield comprises a firstsemiconductor material; bonding the integrated circuit to the top sideof the interposing shield such that the N chip electric pads are inelectrical contact with the N electric conductors; polishing the bottomside of the interposing shield so as to expose the N electric conductorsto the surrounding ambient at the bottom side of the interposing shieldafter said bonding the integrated circuit to the top side is performed;forming N solder bumps on the polished bottom side of the interposingshield and in electrical contact with the N electric conductors; aftersaid forming the N solder bumps is performed, bonding a ceramicsubstrate that includes N substrate pads such that the N substrate padsare bonded to the N solder bumps; and forming M copper regions withinthe interposing shield, wherein M is at least 2, wherein each copperregion comprises copper, wherein a first direction from the top side tothe bottom side is perpendicular to both the bottom side and the topside, wherein each copper region has a length oriented in the firstdirection and a width oriented in a second direction perpendicular tothe first direction, wherein the length exceeds the width of each copperregion, wherein each electric conductor has a length oriented in thefirst direction and a width oriented in the second direction, whereinthe length exceeds the width of each electric conductor.
 11. The methodof claim 10, wherein the length of each copper region is less than thelength of each electric conductor.
 12. The method of claim 10, wherein Nexceeds M.
 13. The method of claim 12, wherein N=M+1.
 14. The method ofclaim 13, wherein M is at least 3, and wherein the N electric conductorsand the M copper regions are distributed in the second direction in aspatial sequence of C1, E1, E2, C2, E3, E4, C3, . . . , wherein Cmdenotes copper region m for m=1, 2, . . . , M, and wherein En denoteselectric conductor n for n=1, 2, . . . , N.
 15. A structure fabricationmethod, comprising: providing an integrated circuit including N chipelectric pads, wherein N is a positive integer, and wherein the N chipelectric pads are electrically connected to a plurality of devices onthe integrated circuit; providing an interposing shield having a topside and a bottom side and having N electric conductors in theinterposing shield, wherein the N electric conductors are exposed to asurrounding ambient at the top side but not being exposed to thesurrounding ambient at the bottom side, wherein N is at least 2, whereinthe interposing shield comprises a first semiconductor material; bondingthe integrated circuit to the top side of the interposing shield suchthat the N chip electric pads are in electrical contact with the Nelectric conductors; polishing the bottom side of the interposing shieldso as to expose the N electric conductors to the surrounding ambient atthe bottom side of the interposing shield after said bonding theintegrated circuit to the top side is performed; forming N solder bumpson the polished bottom side of the interposing shield and in electricalcontact with the N electric conductors; after said forming the N solderbumps is performed, bonding a ceramic substrate that includes Nsubstrate pads such that the N substrate pads are bonded to the N solderbumps; and forming a copper layer sandwiched between, and electricallyinsulated from, the N electric conductors and the N solder bumps. 16.The method of claim 15, wherein a first direction from the top side tothe bottom side is perpendicular to both the bottom side and to topside, wherein the copper layer has a thickness in a range of 10 μm to 15μm in the first direction, and wherein the interposing shield has athickness less than 1 μm in the first direction.